Mapei needed to keep operating during the week so Teepee proposed to install the new racking over three weekends. The new system would be designed to operate Mapei’s current fleet of forklifts, which consisted of reach trucks and low-level order pickers (LLOPs).

Due to three different types of pallets being stored within the racking system, Mapei was concerned how forklift operatives would locate the right pallet onto the correctly designed beam, to avoid overloading.  To overcome this, Teepee installed three different beam colours from their standard range, enabling drivers to easily identify the correct pallet location. As a further precaution weldmesh decking with suitable pallet supports were fitted to all beam levels, to prevent undetected poor quality pallets from collapsing.

Finally, with a centrally positioned aisle in line with the dispatch roller shutter door nominally 4000mm long, Mapei had concerns regarding the protection of racking uprights as a high number of forklifts operated within the vicinity. With frame guards already installed to all uprights, Teepee installed low-level tubular barriers fitted with our optional low-level protection angle to reduce the risk of damaging the racking uprights. Also, we installed concave mirrors to either side of the ‘Drive Thru’ aisles to enable drivers to be aware of one another’s location, as an additional safety measure.

Space was a real challenge with this project and strategic thinking was required to make best use of the available area. Teepee, therefore, proposed a bespoke rail-guided cantilever racking system nom 10,000mm high, with each upright having a base plus 13-1000mm long arms in the height, capable of supporting a uniformly distributed load (UDL) of 3000Kgs per level.

To prevent the bar from rolling off at a high level, welded end stops were fitted to all arms and operating clearances increased to enable individual bundles of bar to be retrieved and stored safely.

With safety our main priority, we also proposed that this free-standing cantilever racking system incorporated detachable base and arms to enable damaged components to be easily replaced, at minimal cost.

The project also required planning ingenuity on two other fronts. The first issue was a limited floor slab load meaning that careful tolerance calculations were an important part of our solution. Secondly, due to manufacturing requirements, the client could only accommodate one transfer aisle. To overcome these issues Teepee installed steel spreader plates underneath all uprights and opted for an articulated forklift truck application. This enabled transfer aisles to be installed two thirds down the length of the racking to increase operating efficiency and reduce the number of forklifts required.

Further safety features included installing full-height mesh guarding to the end of a single entry run of racking to protect the workforce operating within the area, and end of aisle barriers and timber decking above all transfer aisles.

On completion this system allowed LSFE to store 1,008 bundles of raw materials and 5,537 euro pallet locations.

After carrying out an onsite survey Teepee projects department provided Olympus Global within a rail-guided VNA  Man-Up forklift truck solution. This enabled Olympus Global to maximize the available clear headroom of 9,900mm, operating within aisles of 1450mm.

By offering a Man-Up VNA solution this allowed full pallets to be stored and retrieved, with the added advantage of allowing the forklift driver to pick individual SKU’s from mixed pallets. Furthermore, by offering a low profile guide rail system opposed to a wire-guided system, this enabled the VNA forklift to operate at maximum speed without the unnecessary expense of grinding back the floor or the installation of wire guidance.

To create the secure store Teepee installed solid single skin steel partitioning at 3000mm high, then anti-collapse weld mesh guarding 9700mm being supported off the racking uprights to prevent any pallets falling onto personnel operating within the area.

Finally, due to confined space, two bi-part opening doors were installed to enable forklift access, complete with steel protection guards fitted either side.

Teepee provided MWW with 3 different design solutions using a Reach, VNA and Articulated forklift trucks. This enabled MWW to establish the number of pallets being stored, against the cost of forklift trucks & space utilisation.

An articulated forklift was the preferred design offering maximum flexibility against return on investment, enabling both UK and Euro pallets to be stored using one machine, operating within aisles of 2,100mm with a top beam height of 11,850mm.